ENGLISH ELECTRONIC EYELET BUTTON HOLER
Thank you very much for buying a BROTHER sewing machine. Before using your new machine, please read the safety instructions below and the explanations given in the instruction manual. With industrial sewing machines, it is normal to carry out work while positioned directly in front of moving parts such as the needle and thread take-up lever, and consequently there is always a danger of injury that can be caused by these parts. Follow the instructions from training personnel and instructors regarding safe and correct operation before operating the machine so that you will know how to use it correctly. SAFETY INSTRUCTIONS 1. Safety indications and their meanings This instruction manual and the indications and symbols that are used on the machine itself are provided in order to ensure safe operation of this machine and to prevent accidents and injury to yourself or other people. The meanings of these indications and symbols are given below. Indications DANGER CAUTION The instructions which follow this term indicate situations where failure to follow the instructions will almost certainly result in death or severe injury. The instructions which follow this term indicate situations where failure to follow the instructions could cause injury when using the machine or physical damage to equipment and surroundings. Symbols...This symbol ( ) indicates something that you should be careful of. The picture inside the triangle indicates the nature of the caution that must be taken. (For example, the symbol at left means beware of injury.)...this symbol ( ) indicates something that you must not do....this symbol ( ) indicates something that you must do. The picture inside the circle indicates the nature of the thing that must be done. (For example, the symbol at left means you must make the ground connection.) i
2. Notes on safety DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury. CAUTION Environmental requirements Use the sewing machine in an area which is free from sources of strong electrical noise such as high-frequency welders. Sources of strong electrical noise may cause problems with correct operation. Any fluctuations in the power supply voltage should be within 10% of the rated voltage for the machine. Voltage fluctuations which are greater than this may cause problems with correct operation. The power supply capacity should be greater than the requirements for the sewing machine s electrical consumption. Insufficient power supply capacity may cause problems with correct operation. The pneumatic delivery capability should be greater than the requirements for the sewing machine's total air consumption. Insufficient pneumatic delivery capability may cause problems with correct operation. Machine installation should only be carried out by a qualified technician. Contact your Brother dealer or a qualified electrician for any electrical work that may need to be done. The sewing machine weighs more than 87 kg. The installation should be carried out by two or more people. Do not connect the power cord until installation is complete, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury. Be sure to connect the ground. If the ground connection is not secure, you run a high risk of receiving a serious electric shock, and problems with correct operation may also occur. Installation The ambient temperature should be within the range of 5 to 35 during use. Temperatures which are lower or higher than this may cause problems with correct operation. The relative humidity should be within the range of 45% to 85% during use, and no dew formation should occur in any devices. Excessively dry or humid environments and dew formation may cause problems with correct operation. Avoid exposure to direct sunlight during use. Exposure to direct sunlight may cause problems with correct operation. In the event of an electrical storm, turn off the power and disconnect the power cord from the wall outlet. Lightning may cause problems with correct operation. All cords should be secured at least 25 mm away from any moving parts. Furthermore, do not excessively bend the cords or secure them too firmly with staples, otherwise there is the danger that fire or electric shocks could occur. Install the belt covers to the machine head and motor. If using a work table which has casters, the casters should be secured in such a way so that they cannot move. Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation can result. Furthermore, do not drink the oil or eat the grease under any circumstances, as they can cause vomiting and diarrhoea. Keep the oil out of the reach of children. ii
This sewing machine should only be used by operators who have received the necessary training in safe use beforehand. The sewing machine should not be used for any applications other than sewing. Be sure to wear protective goggles when using the machine. If goggles are not worn, there is the danger that if a needle breaks, parts of the broken needle may enter your eyes and injury may result. Turn off the power switch at the following times, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury. When threading the needle When replacing the needle When not using the machine and when leaving the machine unattended CAUTION Sewing If using a work table which has casters, the casters should be secured in such a way so that they cannot move. Attach all safety devices before using the sewing machine. If the machine is used without these devices attached, injury may result. Do not touch any of the moving parts or press any objects against the machine while sewing, as this may result in personal injury or damage to the machine. If an error occurs in machine operation, or if abnormal noises or smells are noticed, immediately turn off the power switch. Then contact your nearest Brother dealer or a qualified technician. If the machine develops a problem, contact your nearest Brother dealer or a qualified technician. Turn off the power switch before carrying out cleaning, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury. Cleaning Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation can result. Furthermore, do not drink the oil or eat the grease under any circumstances, as they can cause vomiting and diarrhoea. Keep the oil out of the reach of children. Maintenance and inspection Maintenance and inspection of the sewing machine should only be carried out by a qualified technician. Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspection of the electrical system. Turn off the power switch and disconnect the power cord from the wall outlet at the following times, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury. When carrying out inspection, adjustment and maintenance When replacing consumable parts such as the loopers and knife Disconnect the air hoses from the air supply and wait for the needle on the pressure gauge to drop to 0 before carrying out inspection, adjustment and repair of any parts which use the pneumatic equipment. If the power switch and air need to be left on when carrying out some adjustment, be extremely careful to observe all safety precautions. Use only the proper replacement parts as specified by Brother. If any safety devices have been removed, be absolutely sure to re-install them to their original positions and check that they operate correctly before using the machine. Any problems in machine operation which result from unauthorized modifications to the machine will not be covered by the warranty. iii
3. Warning labels The following warning labels appear on the sewing machine. Please follow the instructions on the labels at all times when using the machine. If the labels have been removed or are difficult to read, please contact your nearest Brother dealer. 1 2 3 Do not touch the knife or press any objects against the machine while sewing, as this may result in personal injury or damage to the machine. Safety devices Eye guard Finger guard Needle bar guard Belt cover, etc. 4 Be careful not to clamp your fingers when closing the front cover. 5 Be sure to connect the ground. If the ground connection is not secure, you run a high risk of receiving a serious electric shock, and problems with correct operation may also occur. 6 Direction of operation Needle bar guard Eye guard Belt cover (Rear) Finger guard 3122Q Belt cover iv
CONTENTS 1. NAMES OF EACH PART... 1 2. SPECIFICATIONS... 2 2-1. Specifications... 2 2-2. Sewing shape... 3 2-3. Optional parts... 3 2-4. PD-9810, Programmer... 3 2-5. Replacement parts list for specification changes... 4 3. INSTALLATION... 5 3-1. Table processing diagram... 5 3-2. Installing the motor... 6 3-3. Installing the motor pulley... 7 3-4. Installing the control box... 7 3-5. Installing the machine head... 8 3-6. Installing the oil container... 10 3-7. Installing the operation panel... 10 3-8. Tightening the V-belt... 11 3-9. Installing the spool stand... 12 3-10.Installing the hand switch... 12 3-11. Installing the air unit and the valve unit... 12 3-12.Connecting the wiring... 13 3-12-1. Connections inside the control box... 14 3-12-2. Connecting the motor cables... 15 3-12-3. Connecting the air tubes... 15 3-12-4. Securing the cables... 16 3-13.Connecting the air tubes...17 3-13-1. Adjusting the air pressure... 17 3-14.Connecting the power cord... 18 3-15. Installing the programmer (sold separately)... 19 3-16.Installing the foot switch (option)... 19 3-17.Installing the indexer (option)... 20 3-17-1. Installing the indexer main unit... 20 3-17-2. Installing the upper thread presser... 21 3-17-3. Replacing the plate presser and presser plate... 21 3-17-4. Installing the valve unit... 21 3-17-5. Connecting the connectors... 22 3-17-6. Connecting the air tubes... 23 3-17-7. Securing the air tubes and cables... 23 3-17-8. Installing the hand switch... 24 4. LUBRICATION... 25 4-1. Adding oil... 25 4-2. Lubrication... 25 5. CORRECT USE... 27 5-1. Data initialization... 27 5-2. Changing the lower thread and gimp trimming... 27 5-3. Installing the needle... 28 5-4. Threading the upper thread... 28 5-5. Threading the lower thread... 29 5-6. Threading the gimp... 30 5-7. Setting the material... 31 5-8. Setting the installation position for cloth feed plate (L) (-52 specifications)... 33 5-9. Replacing the PROMs... 34 6. OPERATION... 35 6-1. Name and function of each operation panel item... 35 6-2. Starting up... 36 6-3. Program setting method... 37 6-3-1. Parameter table ( Taper bar )... 37 6-3-2. Parameter table ( Straight bar tacking )...40 6-4. Cycle program... 43 6-5. Production counter... 44 6-6. Using the program memos... 44 7. SEWING... 45 7-1. Automatic sewing... 45 7-2. Using the EMERGENCY STOP switch... 46 7-3. Adjusting the thread tension... 47 7-4. Needle and knife position... 48 7-5. Setting the feed bracket to the front position... 49 7-6. Switching between single-pedal and dual-pedal operation... 49 7-7. Using test feed mode... 50 7-8. Using manual mode... 51 7-9. Changing the mode during an operation... 52 7-10. Moving the cloth feed bar (-52 specifications)... 52 8. CLEANING AND MAINTENANCE... 53 8-1. Cleaning... 53 8-2. Draining the oil... 54 8-3. Checking the air filter... 54 9. STANDARD ADJUSTMENTS... 55 9-1. Adjusting the height of the spreader and looper... 55 9-2. Adjusting the needle and looper timing... 56 9-3. Adjusting the loop stroke... 57 9-4. Adjusting the height of the needle bar... 58
9-5. Adjusting the clearance between the looper and needle... 58 9-6. Adjusting the needle guard... 59 9-7. Adjusting the spreader mounting positions... 59 9-8. Adjusting the spreader timing... 60 9-9. Adjusting the needle racking width (stitch width)... 60 9-10. Changing the knife cutting length (Replacing the hammer)... 61 9-11. Adjusting the contact between the knife and the hammer... 62 9-12.Replacing the knife... 63 9-13. Adjusting the cutting pressure... 63 9-14. Adjusting the position of the work clamp plate...64 9-15. Adjusting the cloth opening amount... 65 9-16. Adjusting the trimming of the upper thread... 66 9-17. Adjusting the trimming of the lower thread and gimp... 66 9-18. Adjusting the gimp length after trimming (-02, -52 specifications)... 67 9-19. Lower thread presser (-02, -52 specifications)... 67 9-20. Auxiliary clamp arm (-02, -52 specifications)... 68 9-21. Adjusting the cloth feeding speed (-52 specifications)... 68 9-22. Adjusting the cloth feed bar home position (-52 specifications)... 69 9-23. Adjusting the indexer hole spacing (-52 specifications)... 70 9-24. Adjusting the position of limit switch L (-52 specifications)... 71 9-25. Adjusting the position of limit switch R (-52 specifications)... 71 10. CHANGING FUNCTIONS USING THE MEMORY SWITCHES... 72 10-1.Memory switch table... 73 11. CHANGING FUNCTIONS USING THE DIP SWITCHES... 74 11-1. Panel DIP switches... 74 11-2. Circuit board DIP switches... 75 12. LIST OF ERROR CODES... 77 13. TROUBLESHOOTING... 80
1. NAMES OF EACH PART 1. NAMES OF EACH PART 3123Q (1) Front cover (2) Hand switch (3) Cloth presser switch (4) Start switch (5) EMERGENCY STOP switch (6) Upper shaft pulley (7) Feed bracket (8) Spool stand (9) Power switch (10) Motor (11) Operation panel (12) Control box Fly indexer (-52 specifications) Fly indexer 2380Q 1
2. SPECIFICATIONS 2. SPECIFICATIONS 2-1. Specifications Specification -00-01 -02, -52 Application Men s clothes and ladies clothes Jeans and work clothes Sewing speed 1,000-2,200rpm (100-rpm steps) Stitch length 5-50 mm 5-38 mm L1 14-18 mm L5 28-32 mm L2 18-22 mm L6 32-36 mm L3 22-26 mm L7 36-40 mm L4 26-30 mm Stitch pitch 0.5-2.0 mm Stitch width 1.5-3.2 mm Tacking length 0-20 mm Work clamp height 12 mm 16 mm Starting method Dual switch (cloth presser switch and start switch) or single switch Feed method Intermittent feed by three pulse motors (X, Y, θ) Needle DO X 558 Nm 80 - Nm 120 (Schmetz 558) Safety equipment Built-in emergency stop function and automatic stopping device which stops the machine when the safety circuit is activated Motor Inverter-type induction motor Air pressure Main regulator: 0.5MPa Knife pressure regulator: 0.3MPa Air consumption 43.2 l/ min. (8 cycles/min.) Noise level 85dB at max. speed of 2,200r pm, measured according to ISO 10821 Dimensions 1,200 mm (W) X 590 mm(d) X 1,120 mm (H) Work table legs T-shape height-adjustable type Single-phase 220 V Power supply 3-phase 220 V, 380 V, 400 V Maximum electric power consumption: 1kvA Weight 163.5 kg Fly indexer specifications (-52 specifications) Standard Large size Vertical sewing 50.8 mm 57.15 mm Max. hole spacing Hole spacing margin (2 inch) (2 1/4 inch) Horizontal sewing 152.4 mm 285.75 mm Max. overall feed amount margin (2 inch X 3) (2 1/4 inch X 5) No. of holes 3-4* 1 3-6* 1 Horizontal sewing margin 9-21 mm (9-11 mm* 2 ) No. of holes Vertical sewing margin 30-40 mm Overall feed amount *1 The cloth feed bar F assembly (sold separately) can be processed and used so that 1 to 9 buttonholes can be sewn. *2 L5 - L7 specifications Lower thread trimmer Upper thread trimmer Long type Short type Fly indexer -00 - - - -01 - - -02 - - -52 - * -02 and -52 specifications are further divided into L1 - L7 specifications in accordance with the stitch length. Please be sure to specify the stitch length when ordering. 0792Q 2
2. SPECIFICATIONS 2-2. Sewing shape Eyelet buttonhole Straight buttonhole Without bar tacking With taper With straight bar tacking (*) Without bar tacking With taper With straight bar tacking (*) * The DIP switch settings must be changed. (Refer to page 74.) 2-3. Optional parts Parts name Parts code Two-pedal foot switch S42838-101 Waist belt presser Cloth presser (L3W) set Cloth presser (L4W) set S43701-001 S43704-001 Upper thread nipper S43406-301 Fly indexer Fly indexer assembly for L1, L2 and L5 specifications Fly indexer assembly for L3, L4, L6 and L7 specifications S44279-101 S44281-101 Special lapel cutting device S53906-201 This allows the work clamp to raised and lowered and the sewing machine to be started by pedal operation. When sewing eyelet buttonholes into waist belts with which have differences in thickness, this presser provides secure clamping for the different thickness. It prevents any slippage of the material during sewing. This device prevents the thread from pulling out at the sewing start, thus contributing to a more accurate and higher-quality seam finish. This is an indexer which is specially for use when sewing flys. It allows from one to nine buttonholes to be set, and automatically feeds the material. Using this device makes the sewing of buttonholes for flys much quicker. Eyelet buttonhole and straight buttonhole can be sewn automatically without replacing hammer and knife. It is effective for men s jacket cycle sewing (eyelet buttonholeflower hole). 2-4. PD-9810, Programmer You can use the icon keys to retrieve parameters at a single touch, and to display them as icons on the LED screen so that the settings can be changed easily. It allows you to easily transfer data between different sewing machines. 2381Q 3
2. SPECIFICATIONS 2-5. Replacement parts list for specification changes The sewing machine can be changed to any one of L1 - L7 for -02 and -52 specifications by replacing the specified parts with the appropriate parts given below. -02 specifications Specifications Plate R assembly (buttonhole length) Replacement parts set Plate L assembly Hammer Specification harness L1 S38576-301 S37702-001 (S12) (14-18 mm) S44238-001 S38577-201 S37704-001 (S16) S43337-000 L2 S38578-301 S37704-001 (S16) (18-22 mm) S44239-001 S38579-201 S37706-001 (S20) S43338-000 L3 S38580-301 S37706-001 (S20) (22-26 mm) S44240-001 S38581-201 S37708-001 (S24) S43339-000 L4 S38582-301 S37708-001 (S24) (26-30 mm) S44271-001 S38583-201 S42053-001 (S28) S43340-000 L5 S41470-101 S37197-001 (26) (28-32 mm) S44272-001 S41471-101 S37199-001 (30) S43341-000 L6 S41472-101 S37199-001 (30) (32-36 mm) S44273-001 S41473-101 S37201-001 (34) S43342-000 L7 S41474-101 S37201-001 (34) (36-40 mm) S44274-001 S41475-101 S35093-001 (38) S43343-000 0797Q Note: There is 10 mm of difference in the knife cutting position between L1 - L4 and L5 - L7 specifications. (Refer to page 63.) -52 specifications Specifications Plate R assembly (buttonhole length) Plate L assembly Hammer Specification harness Cloth feed plate R L1 S38576-301 S37702-001 (S12) (14-18 mm) S38577-201 S37704-001 (S16) S43360-000 S43809-001 Note: L2 S38578-301 S37704-001 (S16) (18-22 mm) S38579-201 S37706-001 (S20) S43361-000 S43809-001 L3 S38580-301 S37706-001 (S20) (22-26 mm) S38581-201 S37708-001 (S24) S43362-000 S42139-101 L4 S38582-301 S37708-001 (S24) (26-30 mm) S38583-201 S42053-001 (S28) S43363-000 S42139-101 L5 S41470-101 S37197-001 (26) (28-32 mm) S41471-101 S37199-001 (30) S43364-000 S43809-001 L6 S41472-101 S37199-001 (30) (32-36 mm) S41473-101 S37201-001 (34) S43365-000 S42139-101 L7 S41474-101 S37201-001 (34) (36-40 mm) S41475-101 S35093-001 (38) S43366-000 S42139-101 0799Q There is 10 mm of difference in the knife cutting position between L1 - L4 and L5 - L7 specifications. (Refer to page 63.) 4
3. INSTALLATION 3. INSTALLATION CAUTION Machine installation should only be carried out by a qualified technician. Contact your Brother dealer or a qualified electrician for any electrical work that may need to be done. The sewing machine weighs more than 87 kg. The installation should be carried out by two or more people. Do not connect the power cord until installation is complete, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury. All cords should be secured at least 25 mm away from any moving parts. Furthermore, do not excessively bend the cords or secure them too firmly staples, otherwise there is the danger that fire or electric shocks could occur. Be sure to connect the ground. If the ground connection is not secure, you run a high risk of receiving a serious electric shock, and problems with correct operation may also occur. Install the belt covers to the machine head and motor. 3-1. Table processing diagram The top of the table should be 50 mm in thickness and should be strong enough to hold the weight and withstand the vibration of the sewing machine. Drill holes in the table as shown in the diagram below. 0800Q * There is the special table indicated below. Model code Table/legs assembly 127-981-04902 5
3. INSTALLATION 3-2. Installing the motor 3124Q 1. Insert the four nuts (1) into the work table. 2. Turn the work table upside down to make it easier to install the motor (2). 3. Align the holder plate (3) and the motor plate (4) with the nuts (1), and then install them with the four washers (5), the four spring washers (6) and the four bolts (7). 4. Place the eight accessory cushions (7) and the four accessory cushion collars (8) onto the motor base plate (9), and then install the motor as shown in the illustration. Note: The vibration of the motor may cause the bolts to come loose. Make sure that the bolts are securely tightened. 3125Q 6
3. INSTALLATION 3-3. Installing the motor pulley 3126Q 1. Place the motor pulley (1) onto the shaft of the motor (2) so that the key grooves are aligned, and then tighten the set screws (3) so that the center of the V groove in the motor pulley (1) is aligned as closely as possible with the center of the belt hole in the power table. 2. Install the motor rear cover support (4) with the two flat washers (5) and the two screws (6). Note: Check that the motor rear cover support (4) does not touch the motor pulley (1) or the edge of the motor. 3127Q 3-4. Installing the control box 1. Insert the four nuts (1) into the work table. 2. Open the front and rear covers of the control box (2). 3. Align the control box (2) with the nuts (1), and then install it with the four flat washers (3), spring washers (4) and bolts (5). Note: Be careful not to drop any small parts such as washers onto the circuit board when installing the bolts. 3128Q 7
3. INSTALLATION 3-5. Installing the machine head 2980Q 2981Q 1. Insert the accessory bed base cushions A (1) into the bed base, and then place the machine head on top of the work table. Note: When placing the machine head on top of the work table, have two or more people there to hold the handles and rear of the head as indicated in the illustration. 2. Open the front cover (2), and then use the bolt (3), washer (4), rubber sheet (5), bed stand cushion A (1), large washer (6) and nut (7) to attach the front right corner of the bed base to the work table. 3. Attach the bed base to the work table in two places inside the base in the same way as in step 2. above. 4. Remove the bolt (8) and the washer. Note: The bolt (8) and washer should be kept, as they will be needed again if the machine head is moved. 5. Raise the machine head, and then attach the front left corner of the bed base to the work table in the same way as in the steps above. Note: Make sure that steps 2. to 4. above have been completed before raising the machine head. 6. Install the bed base cover (9) to the rear of the bed (10) with the four screws (11). Note: Be careful not to injure yourself on the spring hinge. 2982Q 8
3. INSTALLATION Raising the machine head When machine head is lowered 2983Q When machine head is raised 2984Q 1. While holding the handles of the machine head (1) with both hands, gently raise the machine head. Note: Be sure to turn the power supply off before raising the machine head. 2. If you wish to keep the machine head in the raised position, insert the head support lever (2) securely into the hinge lever support shaft (3). Note: Always check that the head support lever (2) and the hinge lever support shaft (3) are meshed. Lowering the machine head Pull the machine head down toward you gently, remove the head support lever (2) from the hinge lever support shaft (3), and then gently lower the machine head. Note: Do not hold the machine head by the feed bracket (4) or X feed shaft A (5) when it is being raised and lowered. 9
3-6. Installing the oil container 2986Q 3. INSTALLATION 1. Install the oil draining cap support (2) to the base of the bed base (1) with the two screws (3). 2. Screw the oil container (4) into the oil draining cap support (2). 3. Push the oil draining spring pin (5) into the bed base (1) until the pin is flush with the surface of the base. 4. Lower the machine head. (Refer to "Lowering the machine head" on previous page.) 2985Q 3-7. Installing the operation panel Top of work table Table 2987Q The operation panel can be installed to either the top or bottom of the work table. 1. Install the rear frame (1) to the work table (top or bottom) with the four wood screws (2). 2. Install the front frame assembly (3) to the rear frame (1) with the four screws (4). * The vertical orientation of the front frame assembly (3) is the same whether it is installed to the top or the bottom of the work table. * Pull the harnesses such as the ground harness out of the way so that the operation panel side cover (5) can be opened and closed. 3. Insert the connector cord (6) into the control box through the hole at the side of the box. Bottom of work table Table 2988Q 10
3. INSTALLATION 3-8. Tightening the V-belt Approx.10 mm 2990Q 2991Q 1. Open the rear cover. 2. Pass the V-belt (1) through the base of the bed base and through the hole in the work table. 3. Place the V-belt (1) onto the motor pulley (2). 4. Check that there is approximately 10 mm of deflection in the V-belt (1) when it is pushed in the middle with a load of 10 N. If the tightness needs adjusting, loosen the two nuts (3) and move the motor up or down. After adjusting, tighten the nuts (3). Note: Check that the motor rear cover support (4) does not touch the motor pulley (1) or the edge of the motor. 5. Install the motor cover (5) with the three screws (6). Note: After a long period of use, the V-belt will become run in and will loosen around the motor pulley. When this happens, turn off the power and adjust by the procedure given in step 4. above. 11
3. INSTALLATION 3-9. Installing the spool stand 1. To assemble the spool stand (1), follow the instructions in the manual that came with the spool stand (1). 2. Secure the spool stand (1) to the rear right corner of the work table with the washer and nut (2). 2989Q 3-10. Installing the hand switch Install the hand switch (1) with the two screws (2). 3129Q 3-11. Installing the air unit and the valve unit 2387Q Valve unit Air unit 2992Q Installation position 1. Install the air unit (1) to the underside of the work table with the two screws (2). 2. Install the valve unit (3) with the two screws (4). 3. Connect air tube No. 15 to the intermediate joint (5) of the air unit (1) and to the joint (6) of the valve unit (3), and connect air tube No. 16 to joints (7) and (8). Connecting the valve cables Insert the cable (9) which is coming out of the valve unit to the 2-pin connector (10) of the valve cable assembly. 12
3. INSTALLATION 3-12. Connecting the wiring 2994Q 1. Pass the cable and air tube which are coming out of the belt cover (1) and the machine head (2) through the cable hole (3) in the work table. 2. Pass the cables and air tube which are coming out of the feed bracket (4) and the left side of the bed base (5) and the cable for the hand switch (6) through the cable hole (7) in the work table. Note: Leave enough looseness in the cables so that they will not be pulled when the machine head is tilted back. Adjust the looseness after all connections to the control box are complete. 3130Q 3. Connect the hand switch connector (8) to the control box connector. 4. Install the power switch (9) to the underside of the work table with the two screws (10). 5. Secure the cables using staples (11) (in four locations). 3131Q 13
3. INSTALLATION 3-12-1. Connections inside the control box 2997Q 1. Open the rear cover (1) of the control box. 2. Pass the cables through the holes (2) and (3) in the side of the control box. 3. Loosen the screw (5), and then connect the three ground cables (4) that are coming from the machine head. 4. Securely insert each of the connectors (6) - (14) as indicated below. Machine head connectors Connector (6) (12-pin with [1] mark) Connector (7) (5-pin with [2] mark) Connector (8) (9-pin with [3] mark) Connector (9) (12-pin with [4] mark) Connector (10) (5-pin with [6] mark) Connector (11) (5-pin with [7] mark) Connector (12) (16-pin with [8] mark) Connector (13) (18-pin with [9] mark) Connector (14) (10-pin) (Connection indications) * This is indicated on the P.C. board. P1 (ORG) P2 (SYNCHRO) P3 (HEAD) P4 (AIR) P6 (YPM) (BLUE) P7 (XPM) P8 (EXINA) P9 (EXINB) P18 (PANEL) 2998Q PMD circuit Board 5. Insert the connector (15) (6-pin with [1][R] mark) to the connector (16). 6. Loosen the middle screw (19) and then install the ground cable (17) and the three ground cables (18) from the operation panel. 7. Secure the cables with the cable clamp as shown in the illustration. Note: When securing the cables, do not let any of the cables touch the components on the circuit board or the heat sink. Furthermore, adjust the lengths of the cables from outside the control box so that there is no looseness in the cables inside the control box. 2999Q 14
3. INSTALLATION 3-12-2. Connecting the motor cables 1. Remove the screws (1), and then open the terminal block cover (2) of the motor. 2. Loosen the screw (3) and connect the ground cable (4) for the motor. 3. Loosen the screw (5) and connect the ground cable (6) from the control box. 4. Connect the cables so that the cable marks (U, V, W) match the symbols on the screw terminals. 5. Close the cover (2). Note: Be careful not to clamp the cables when closing the cover. 3000Q 3-12-3. Connecting the air tubes Connect the air tubes to the joints of the solenoid valve assembly, using the illustration below as a reference. Numbers are marked on each of the air hoses which come out of the sewing machine. < -00, -01 > 0826Q Plug 4 0827Q Label No. Solenoid valve 5 Upper thread trimming 4 Upper thread tightening 3 Lower thread trimming *1 Cloth spreading 2 (Auxiliary clamp arm *2) 1 Work clamp *1 If the lower thread trimmer is not installed, solenoid valve [3] is not used. *2 The auxiliary clamp arm can only be used for machines with -02 specification. < -02 > 0828Q 0829Q 15
3. INSTALLATION 3-12-4. Securing the cables 3132Q Note: Leave enough looseness in the cables so that they will not be pulled when the machine head is tilted back. 1. Pass the cable through the cable holder (1), and then secure the cable holder (1) to the underside of the work table with the screw. 2. Pass the air tube and the hand switch cable through the cable holder (2), and then secure the cable holder (2) to the underside of the work table with the screw. 3. Place the machine head cable together with the valve cable assembly and motor cable, pass them all through the cable holder (3), and then secure the cable holder (3) to the underside of the work table with the screw. 3002Q 3003Q Insert the specification harness (1) into the control box connector (2). Note: Check that the label number on the specification harness (1) matches the movable knife (R) (3), movable knife (L) (4), thread handler (5), work clamp (R) (6), work clamp (L) (7) and movable knife driving cam (8) numbers before inserting the specification harness (1). (If a connector with an incorrect label number is connected, it may cause problems such as damage to the sewing machine or thread trimming errors.) Specification -02 Label No. of harness Right/left work clamp No. Right/left movable knife No. Thread handler No. -00, -01 0 L1 1 1 L2 2 2 L3 3 3 L4 4 4 L5 5 5 L6 6 6 L7 7 7 * There is 10 mm of difference in the knife installation positions between L1 - L4 and L5 - L7. 3004Q 16
3. INSTALLATION 3-13. Installing the air tubes Connect the air tube from the compressor to the air unit underneath the work table. Closed Open 1. Turn the nut (1) at the end of the air tube, and then connect the tube to the valve (2). 2. Open the air cock (3) on the compressor. Check that there is no air leaking from the valve connection. 3. Open the cock (3) by turning it in the direction of the arrow. The meter needle will move clockwise. 4. Adjust the air pressure. 3005Q 3-13-1. Adjusting the air pressure Set the air pressure for the knife pressure adjustment regulator (3) to the lowest pressure at which the knife can still cut the material. Set the standard air pressure for the main regulator (1) to 0.5 MPa. To increase the air pressure (0.5MPa) (0.3MPa) 3006Q 1. Gently lift the knob (2) of the main regulator (1) and turn it in the direction of the arrow in the illustration. The pressure will increase when the knob (2) is turned clockwise. 2. Gently lift the knob (4) of the knife pressure adjustment regulator (3) and turn it in the direction of the arrow in the illustration. The pressure will increase when the knob (4) is turned clockwise. * The pressure for the knife pressure adjustment regulator (3) is adjusted to 0.3 MPa. Be careful not to increase this pressure needlessly, otherwise poor cutting performance or damage to the knife may result. To decrease the air pressure To close To loosen To tighten (0.5Mpa) (0.3Mpa) 3007Q 1. Close the cock (5). (The needle will remain at the high pressure position.) 2. Turn the knob screw (6) in the direction of the arrow in the illustration to loosen it. Make sure that you turn it in the correct direction. The air will escape from the reservoir and the needle will drop. 3. Tighten the knob screw (6). 4. To reduce the air pressure, gently lift knob (2) or knob (4) and turn it counterclockwise. 5. Open the cock (5). Air will enter the reservoir and the needle will move 17
3. INSTALLATION 3-14. Connecting the power cord CAUTION Contact your Brother dealer or a qualified electrician for any electrical work that may need to be done. Be sure to connect the ground. If the ground connection is not secure, you run a high risk of receiving a serious electric shock, and problems with correct operation may also occur. Do not connect the power cord until installation is complete, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury. 0838Q 1. Attach an appropriate plug to the power cord (1). (The green and yellow wire is the ground wire.) 2. Insert the plug into properly-grounded AC power supply. Note: Do not use extension cords, otherwise machine operation problems may result. Single phase Green and yellow wire (ground wire) 3133Q Three phase Green and yellow wire (ground wire) 3134Q 18
3. INSTALLATION 3-15. Installing the programmer (sold separately) [Vertical] [Flat] 3010Q 3011Q 3012Q 1. Install the programmer support (2) to the work table with the two screws (1). 2. Insert the programmer connector (4) securely into the left side of the operation panel (3). 3-16. Installing the foot switch (option) Insert the connector (3) of the foot switch (2) into the control box connector (1). 3135Q 19
3. INSTALLATION 3-17. Installing the indexer (option) 3-17-1. Installing the indexer main unit 3015Q 1. After disconnecting air tubes [20] and [21], insert the two plugs (3) into joints (1) and (2). In addition, remove parts (4), (5) and (6) indicated in the illustration. 2. Remove the screws (7) from feed bracket cover (L) (8), and then install feed base (L) (9). 3016Q 3. Remove the screws (10) from feed bracket cover (R) (11), and then install feed base (R) (12). 3017Q 4. Pass the cloth feed bar (13) between the rollers of feed bar guide (R) (14) and feed bar guide (L) (15), and place it on top of feed base (L) (9) and feed base (R) (12). * Push down the chuck pin (16) and check that it goes smoothly into all of the holes in the cloth feed bar (13). If it does not go in smoothly, re-adjust the installation positions of feed base (L) (9) and feed base (R) (12). 3018Q 20
3. INSTALLATION 3-17-2. Installing the upper thread presser 3019Q 1. Loosen the screw (1), and then remove the thread guide (2). 2. Install the upper thread presser support (3) with the screw (1). * Adjust the height of the upper thread presser support (3) so that it presses against the upper thread presser plate (5) when the upper thread take-up lever (4) is lowered. 3020Q 3-17-3. Replacing the plate presser and presser plate Remove the plate presser (1) and presser plate (U) (2), and replace them with plate presser (I) (3) and presser plate (I) (4). 3021Q 3-17-4. Installing the valve unit Installation position 3022Q 2400Q 1. Install the valve unit (1) with the screw (2). 2. Remove the stopper plug (with the P mark) (4) from the valve unit (3), and then install the joint (5). 3. Connect the 6mm-diameter air tube (7) to joints (5) and (6). 21
3. INSTALLATION 3-17-5. Connecting the connectors 3023Q 1. Insert the 3-pin connectors [8], [9] and [10] of the valve harness into the solenoid valves of the valve unit (1) so that the label numbers match. 2. Insert the 15-pin connector (2) into the connector of the indexer cord (3). 3. Open the rear cover (4) of the control box. 4. Insert the connector (5) of the indexer cord (3) in the position shown in the illustration. 5. Secure the cord with the cord clamp. 3024Q 6. Insert the two pins of limit switch (R) (6) and the two pins of limit switch (L) (7) into the 15-pin connector terminals with matching numbers. 7. Connect the three pins of the cylinder sensor (8) into the 15-pin connector so that the cable colors match the connector numbers as given in the table below. * If the cable colors are red, white and black, refer to the colors in brackets. Note: First disconnect the connector before inserting the pins, and then after inserting the pins, re-connect the connector. Switch pin No. Cable color 15-pin Connector Limit switch 7 White 7 (R) (6) 12 Black 12 Limit switch 10 White 10 (L) (7) 15 Black 15 Brown (Red) 4 Cylinder Black (White) 9 sensor (8) Blue (Black) 14 8. Secure the cable with the cable clamp (9). 3025Q 22
3. INSTALLATION 3-17-6. Connecting the air tubes 0855Q Connect air tubes [50], [51], [52] and [53] to the places with the corresponding numbers on the valve unit. Label No. Solenoid valve type [50], [51] For cloth feed drive cylinder [52] For chucking cylinder [53] For holding cylinder 0856Q 3-17-7. Securing the air tubes and cables 3026Q 1. Remove the screw (length 8 mm) (1). 2. Secure the air tube (2) and cable (3) with the cord holder (4), screw (length 16 mm) (5) and washer (6). * Leave enough slack in the air tube (2) and cable (3) at this time to allow for the movement of the feed bracket (7). 23
3. INSTALLATION 3003Q 3004Q Insert the indexer specification harness (1) into the control box connector (2). * If another specification harness has been inserted into this connector, first disconnect this harness and then insert the indexer specification harness (1). Note: Check that the label number on the indexer specification harness (1) matches the movable knife (R) (3), movable knife (L) (4), thread handler (5), work clamp (R) (6), work clamp (L) (7) and movable knife driving cam (8) numbers before inserting the specification harness (1). (If a connector with an incorrect label number is connected, it may cause problems such as damage to the sewing machine or thread trimming errors.) Specification -52 Label No. of harness Right/left work clamp No. Right/left movable knife No. Thread handler No. L1 1 1 L2 2 2 L3 3 3 L4 4 4 L5 5 5 L6 6 6 L7 7 7 * There is 10 mm of difference in the knife installation positions between L1 - L4 and L5 - L7. * If using both an upper thread clamping device and a fly indexer, L5 to L7 cannot be used. 3-17-8. Installing the hand switch 1. Install the hand switch support plate (1) with the two screws (2) in the position shown in the illustration. 2. Install the hand switch (3) to the hand switch support plate (1) with the two screws (4). 3027Q 24
4. LUBRICATION 4. LUBRICATION CAUTION Turn off the power switch before starting lubricating, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury. Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation can result. Furthermore, do not drink the oil or eat the grease under any circumstances, as they can cause vomiting and diarrhoea. Keep the oil out of the reach of children. Use only specified Brother oil (Nisseki Mitsubishi Sewing Lube 10 N; VG 10) for the machine oil. 4-1. Adding oil Check the oil level by looking at the sight glass. If the oil level is low, replenish the oil supply. Filling the arm oil tank Filling the bed base oil tank 3028Q Pour approximately 10 cc of machine oil into the arm oil tank (1) (until it is about four-fifths full). 3029Q 1. Raise the machine head. 2. Pour approximately 20 cc of machine oil into the bed base oil tank (2) (until it is about four-fifths full). 3. Lower the machine head. 4-2. Lubrication Oil these parts once a day. Oil the moving parts of the needle bar, looper and spreader mechanisms and also the cam groove, roller, the felt at the base of the wick and the wick before using the sewing machine for the first time, and also after long periods of non-use. When oiling, some oil will get onto the thread. Carry out a test sewing to ensure that your material does not get stained with oil. Oiling the needle bar and cam Add 2-3 drops of oil in the places indicated by the arrows. 0861Q 25
4. LUBRICATION Oiling the looper, spreader and looper base <Removing the work clamp plates> 3031Q 3030Q 1. Turn the upper shaft pulley (1) toward you until the mark on the pulley (A) is aligned with the notch in the pulley cover (2). 2. Move the feed bracket (3) toward you. 3. Turn the left and right plate pressers (4) in the directions indicated by the arrows. 4. Lift up the clamp lever (6) and the notched section (7) of the right work clamp plate (5), remove the right work clamp plate (5) from the pin (8), and then pull the right work clamp plate (5) toward you to remove it. Note: If the lower thread trimmer has been installed, move presser plate U (9) to a position where it can be removed without its touching the needle. Raise presser plate U (9), pass the needle through the hole, and then remove presser plate U (9) from the pin (8). 5. Remove the left work clamp plate (10) in the same way as the right work clamp plate (5) was removed. 3032Q 3035Q 0865Q 3033Q 3034Q 6. Open the front cover. 7. Turn the looper base and add a few drops of oil to the spreader driving cam (11), and to the supports for the looper link (12) and spreader link (13). 8. Add a few drops of oil to the shafts of the right spreader (14), left spreader (15) and LS-holder bracket (16). 9. Fill the felt tank (17) on the looper base with oil also. 10. Add 5-6 drops of oil to the felt (18) which is attached to the sliding surfaces of the looper base and the bed. 11. Close the front cover. 12. Install the work clamp plates by carrying out the steps 5., 4. and 3. in that order. 26
5. CORRECT USE 5. CORRECT USE 5-1. Data initialization When using the sewing machine for the first time, initialize the data by following the procedure below. 1. While pressing the RESET key (1), turn on the power switch. * While the data is being initialized, all LEDs will illuminate and the buzzer will sound a series of short beeps. * All parameters, memory switches, cycle programs and the production counter will be initialized. 2. When the data writing is complete, the buzzer will stop and the machine will go to the normal startingup condition. Note: The data is retained for approximately one month after the power supply is turned off. If more than one month passes since the power supply was last turned on, "E-59" may be 3036Q displayed the next time the power is turned on. If this happens, you will need to re-initialize the data. 5-2. Changing the lower thread and gimp trimming The sewing machine is set to lower thread and gimp trimming when it is shipped from the factory. (DIP switch C (3) No. 6 is set to ON.) For setting the lower thread and gimp thread trimming to OFF, carry out the following procedure. Note: For -00 specification, be sure to set the lower thread and gimp thread trimming to OFF. 1. Turn off the power. Trimming 2. Remove the six screws (1). 3. Open the rear plate (2) of the control box. 4. Set DIP switch C (3) No. 6 on the circuit board to OFF. 5. Close the rear plate (2) and tighten the six screws (1). No trimming 3037Q 27
5. CORRECT USE 5-3. Installing the needle CAUTION Turn off the power switch before installing the needle, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury. 3038Q 3039Q 3040Q Use only Schmetz DO x 558 Nm80 - Nm120 needles. 1. Raise the finger guard (1). 2. Loosen the screw (2), and then remove the needle (3). 3. Insert the new needle (3) as far as it will go so that the groove is facing toward you. 4. Securely tighten the screw (2). 5. Remove the work clamp plates. (Refer to page 26.) Note: After removing the work clamp plates, check that the index mark (4) on the machine head is aligned with the index mark (5) on the looper base before inserting the needle (3) (when the looper base is turned fully to the right). 6. Lower the finger guard (1). 5-4. Threading the upper thread CAUTION Turn off the power switch before threading the thread, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury. Thread the upper thread as shown in the illustration below. * Use the accessory needle threader (1). 0875Q <-52 specifications> 0876Q (1) 0874Q 2403Q 0878Q 28
5. CORRECT USE 5-5. Threading the lower thread Remove the work clamp plates (refer to page 26), and then thread the lower thread as shown in the illustration below. For upper thread trimming specifications (-00) 0880Q 0879Q 0881Q For upper and lower thread trimming specifications (-01, -02 and -52) 0883Q 0882Q 0881Q 29
5. CORRECT USE 5-6. Threading the gimp Remove the work clamp plates (refer to page 26), and then thread the gimp as shown in the illustration below. Once threading is complete, replace the work clamp plates. <-00,-01> 0884Q 0885Q <-02,-52> Pass the gimp through the hole of the thread tension stud (1). Refer to 9-18. Adjusting the gimp length after trimming (Page 67). 3041Q 30
5. CORRECT USE 5-7. Setting the material <-00, -01, -02 specifications> 10-30 mm 3042Q 3043Q 1. Insert the material so that it touches the right and left cloth guides (1). 2. The sewing margin can be adjusted to within 10-30 mm. 3. Loosen the screws (2) at left and right and move the cloth guides (1) back and forth to adjust the sewing margin. <-52 specifications> 0892Q 9-21 mm for L1 - L4 9-11 mm for L5 - L7 3044Q 30-40 mm 1. Place the material (fly) on top of the feed bracket (1), and then feed the material (fly) in until it reaches horizontal cloth set guide (L) (2) and horizontal cloth set guide (R) (3). * Check that the right edge of the material (fly) is straight against the left edge of the vertical cloth set guide (4) at this time. 2. The vertical sewing margin can be adjusted between 9-21 mm for L1 - L4 and 9-11 mm for L5 - L7. Loosen the four screws (5), and then move horizontal cloth set guide (L) (2) and horizontal cloth set guide (R) (3) forward or back to adjust. 3. The horizontal sewing margin can be adjusted between 30-40 mm. Loosen the two screws (6), and move the vertical cloth set guide (4) to the left or right to adjust. 31
5. CORRECT USE Cloth setting position Left setting position Right setting position 0893Q The sewing start position can be set to either the left setting position or the horizontal setting position. (Refer to page 73.) When set to the left setting position This is the normal setting position for the cloth. * After the last buttonhole is sewn, the cloth feed bar returns to the left setting position. Horizontal setting position The cloth is set to both the left setting position and right setting position. * The next piece of cloth is set at the position that the last buttonhole was sewn. 0894Q 32
5. CORRECT USE 5-8. Setting the installation position for cloth feed plate (L) (-52 specifications) The installation position for cloth feed plate (L) can be set to one of four positions depending on the spacing between buttonholes and the number of buttonholes to be sewn. When the spacing between buttonholes and the number of buttonholes sewn have been changed, the installation position for cloth feed plate (L) should also be changed. Refer to the illustration and table below at this time. Standard Large size 3045Q 3046Q Install the cloth feed plate (L) (1) to the cloth feed bar (3) with the screws (2). Installation position <Standard specification> Hole spacing No. of holes 38.1 mm 44.45 mm 50.8 mm 3 (D) (D) (C) 4 (C) (B) (A) <Large size specification> Hole spacing No. of holes 38.1 mm 44.45 mm 50.8 mm 57.15 mm 3 (L) (K) (L) (L) 4 (L) (K) (J) (I) 5 (J) (I) (H) (F) 6 (G) (F) (E) 0897Q (A) 207-217 mm (B) 192.5-202.5 mm (C) 167.5-177.5 mm (D) 142.5-152.5 mm (E) 346.5-356.5 mm (F) 321.5-331.5 mm (G) 279.5-289.5 mm (H) 270.5-280.5 mm (I) 234.5-244.5 mm (J) 209.5-219.5 mm (K) 195-205 mm (L) 184.5-194.5 mm 33